Paper Making Machine Water Removal and Drying

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Solution Overview

Problem

Current paper production methods, particularly for tissue paper, are energy-inefficient and lack flexibility in producing both structured and unstructured paper grades, with TAD machines requiring high thermal and electrical power and being inflexible to changing industrial needs.

Innovation Solution

A paper production system with a formation zone, a zone for forced water removal, and a drying zone, utilizing a capillary roller and a pressure element with a counter-roller to efficiently remove water and dry the fibrous material, allowing for the production of high-quality structured and crepe paper with reduced energy consumption and increased flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If TAD machines are used to produce high quality structured paper, then paper quality is improved, but thermal and electrical power consumption increases

Engineering Contradiction:

Improvepaper qualityVSAvoidthermal and electrical power consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The drying process is segmented into multiple zones (formation zone, forced water removal zone with capillary roller and pressure element, drying zone) allowing each zone to perform a specific function efficiently, reducing overall energy consumption while maintaining paper quality

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the energy-intensive TAD hot air flow system with a mechanical water removal system using a capillary roller and pressure element that physically extract water from the fibrous material, significantly reducing thermal and electrical power requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If TAD machines are used for high quality paper production, then manufacturing capability is improved, but production flexibility deteriorates

Engineering Contradiction:

Improvehigh quality paper production capabilityVSAvoidproduction flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The machine is designed with universal components that can be configured for different paper grades. The formation zone, forced water removal zone, and drying zone can be adjusted to produce both structured high-quality paper and unstructured crepe paper, providing multi-functionality and production flexibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The machine incorporates adjustable and reconfigurable elements that allow dynamic adaptation between different production modes. The system can switch between producing structured paper with optimized fiber arrangement and unstructured crepe paper based on industrial needs, enhancing versatility

Inventive Principle:

Principle #15Dynamics

3Reliability

If conventional drying systems are used, then drying function is provided, but energy efficiency deteriorates

Engineering Contradiction:

Improvedrying functionVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The forced water removal zone with capillary roller and pressure element performs preliminary water removal before the drying zone. This preliminary action removes a significant portion of water mechanically, reducing the energy required in the subsequent thermal drying phase and improving overall energy efficiency

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system achieves high-quality paper production with reduced thermal and electrical power usage, enabling adaptability to various paper grades and improving energy efficiency by optimizing water removal and drying processes.

Implementation Method 1

a capillary roller (44) and respectively a pressure element (4S) with relative counter-roller (4C) acting consecutively on the layer of fibrous material upstream of the drying step

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

a pressure element (4S) with relative counter-roller (4C) acting consecutively on the layer of fibrous material

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

a drying zone downstream of the forced water removal zone, in which means for drying the layer of fibrous material formed in the formation zone are arranged

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20240003085A1Paper making machine and process

Publication Date: 2024.01.04 TOSCOTEC

AI summary

Paper making machine comprising a forming zone in which a layer of fibrous material is formed, a zone for forced removal of water from the fibrous material layer downstream of the forming zone, a drying zone downstream of the forced removal of the water, and a paper collection zone downstream of the drying zone, and means for transporting the layer of fibrous material through said zones of the machine along a path that follows a predetermined transport direction (MD). The forced water removal zone comprises, in turn, two consecutive zones (Z1, Z2) along said transport direction (MD), in which a capillary roller (44) and a pressure element (4S) with a respective counter-roller (4C) are respectively arranged, acting consecutively on the layer of fibrous material upstream of the drying zone.